Вы находитесь на странице: 1из 251

Process Simulation using HYSYS V8

Process Simulation
Using Aspen HYSYS V8

Why Aspen HYSYS?

Eng. Ahmed Deyab Fares


Process Simulation Consultant

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 1


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Aspen HYSYS is a market-leading process modeling tool for conceptual


design, optimization, business planning, asset management, and
performance monitoring for oil & gas production, gas processing,
petroleum refining, and air separation industries. Aspen HYSYS is a core
element of AspenTechs aspenONE Process Engineering applications.

Objectives
Learn to build, navigate and optimize process simulations using Aspen
HYSYS
Learn the efficient use of different HYSYS functions to build steady
state process simulations

Who Should Attend


New engineering graduates/technologists who will be using Aspen
HYSYS in their daily work
Process engineers doing process design and optimization projects and
studies
Plant engineers checking plant performance under different operating
conditions
R&D engineers and researchers using Aspen HYSYS for process
synthesis

Prerequisites
A background in chemical engineering or industrial chemistry

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 2


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Content:

Getting Started

Propane Refrigeration Loop

Refrigerated Gas Plant

Oil Characterization

Pre-Heat Train

Atmospheric Towers & Side operations

Gas Gathering

Optimization

NGL Fractionation Train

Oil Stabilization Optimization

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 3


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Getting Started

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 4


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Workshop
The Getting Started module introduces you to some of the basic concepts
necessary for creating simulations in HYSYS. You will use
HYSYS to define three gas streams to be used as feeds to a gas plant. In
addition, you will learn how to determine properties of these streams by
using the Phase Envelope and the Property Table utilities.

Learning Objectives
Define a fluid package (property package, components, hypotheticals).
Add streams.
Understand flash calculations.
Attach stream utilities.
Customize the Workbook.

Example:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 5


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

We have a stream containing 15% ethane, 20% propane, 60% i-butane

and 5% n-butane at 50F and atmospheric pressure, and a flow rate of

100lbmole/hr. This stream is to be compressed to 50 psia and then

cooled to 32F. The resulting vapor and liquid are to be separated as

the two product streams. Neglect the pressure drop inside the

condenser.

Fluid pkg: Peng Robinson

* What are the flow rates and molar compositions of two product
streams?

Component Vapor Liquid

Ethane

Propane

I-Butane

N-Butane

Total Flow rate

* Create a case study to see the effect of changing temperature of


the cooler out stream on the molar flow of the liquid product
stream, and write your comment.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 6


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

To start the program, From Start Menu, Select All Programs >>
Aspen Tech >> Process Modeling V8.x >>>> Aspen HYSYS >>
Aspen HYSYS

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 7


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

1- First, Start a new case

2- Add the Components

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 8


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

3- Choose the system components from the databank:

Now, select the suitable fluid package

When you have established a component list, you combine the component
list with a property package. The property package is a collection of
methods for calculating the properties of the selected components. The

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 9


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

combination of the component list and the property package, along with
other simulation settings, is called the fluid package.

The built-in property packages in HYSYS provide accurate


thermodynamic, physical and transport property predictions for
hydrocarbon, non-hydrocarbon, petrochemical and chemical fluids.

The database consists of an excess of 1500 components and over 16000


fitted binary coefficients. If a library component cannot be found within the
database, a comprehensive selection of estimation methods is available for
creating fully defined hypothetical components.

There are about 33 property packages inside HYSYS database; the question
now is HOW TO SELECT THE SUITABLE FLUID PACKAGE?

We can select the suitable one by specifying:

1- Process / Application type


2- Temperature and Pressure Range

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 10


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 11


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

ASPEN HYSYS contains an assistant tool to help you in the selection f


the suitable FP, called Methods Assistant:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 12


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

In this case, select Peng-Robinson

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 13


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now you can start drawing the flow sheet for the process by clicking the
Simulation button:

Now add a material stream to define the composition and the conditions
of the feed stream

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 14


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

From the palette:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 15


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 16


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 17


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 18


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 19


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 20


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now you can view the results by double clicking on the separator, in
the worksheet tab:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 21


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Save Your Case!

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 22


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Case Study
We need to study the effect of changing the Temperature of the
cooler out stream (stream no 3) on the flow rate of the liquid
product stream.

Use range: from -30 to 30 oC with step size =5 oC

To create a case study in HYSYS you can simply click on Case


Studies button on the Home menu:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 23


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the two variables:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 24


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Specify the range of the study:

Click run, and then you can view results from the Results tab

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 25


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 26


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Click Results Plot to view graph

Comment:

As we see, when the temperature increases the liquid flow rate


decrease, the liquid start to decrease @ -15 oC, and @ 15 oC there will be
no liquid product and all the product will be vapor.

This is a simple case; you can create your own case study with the same
steps.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 27


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

You can change the scale of axis & the curve color by right click on the
plot area and click graph control:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 28


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

You can also print this plot from the same menu:

Save Your Case!

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 29


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Refrigerated Gas Plant

2
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 30
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Workshop
In this simulation, a simplified version of a refrigerated gas plant is going
to be modeled. The purpose is to find the LTS (Low Temperature
Separator) temperature at which the hydrocarbon dew point target is met.
The Sales Gas hydrocarbon dew point should not exceed -15C at 6000
kPa. The incoming gas is cooled in two stagesfirst by exchange with
product Sales Gas in a gas-gas exchanger (Gas-Gas) and then in a propane
chiller (Chiller), represented here by a Cooler operation. A Balance
operation will be used to evaluate the hydrocarbon dew point of the product
stream at 6000 kPa.

Learning Objectives
Add a hypothetical component
Install and converge heat exchangers.
Understand logical operations (Balances and Adjusts).
Use the Case Study tool to perform case studies on your
simulation.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 31


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Example:

The feed stream enters an inlet separator, which removes the free
liquids. Overhead gas from the Separator is fed to the Chiller where it is
cooled to -20oC, which will be modeled simply as a Cooler (Pressure
Drop=35 kPa). The cold stream is then separated in a low-temperature
separator (LTS). Overhead gas from the LTS is fed to the heater
(Pressure drop=5kPa) where it is heated to 10oC to meet Sales Gas
Specifications.
Feed Stream:
Temperature Pressure Molar Flow Rate
15oC 6200 kPa 1440 kgmole/h

Composition:
Component Mole Component Mole
N2 0.0066 n-Butane 0.0101

H2S 0.0003 i-Pentane 0.0028

CO2 0.0003 n-Pentane 0.0027

Methane 0.7575 n-Hexane 0.0006

Ethane 0.1709 H2O 0.0000

Propane 0.0413 C7+ (NBP=110oC) 0.0001

i-Butane 0.0068
FP: Peng Robinson
- Calculate the duty rejected from the chiller
- Calculate the duty Absorbed inside the Heater

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 32


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

To start the program, From Start Menu, Select All Programs >>
Aspen Tech >> Process Modeling V8.0 >>>> Aspen HYSYS >>
Aspen HYSYS

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 33


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

4- First, Start a new case

5- Add the Components

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 34


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

6- Choose the system components from the databank:

After adding the pure components (N2, H2S, CO2, C1, C2, C3, n-C4, i-C4,
n-C5, i-C5, n-C6, H2O) we have to add the last component (C7+) which is
not a pure component as it represents all components above C7 including
C7 in the feed.
To define C7+ we have to create it as a hypothetical component as the
following:
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 35
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

From the drop menu select Hypothetical instead of pure components

Select create and edit hypos

Click on New Hypo

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 36


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

After adding a hypo component you can edit the name, add the properties
you have, and estimate the unknown properties as follows:

Finally add the hypo component to the component list

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 37


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now, select the suitable fluid package

In this case, select Peng-Robinson

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 38


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now you can start drawing the flow sheet for the process by clicking the
Simulation button:

Now add a material stream to define the composition and the conditions
of the feed stream
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 39
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

From the palette:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 40


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

From the palette select the separator:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 41


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add a cooler:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 42


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the LTS Separator:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 43


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add a heater:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 44


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 45


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

- The duty rejected from the chiller = 4.186 e6 (4.186 *106) kJ/hr
- The duty Absorbed inside the Heater = 2.287 e6 (2.287 *106) kJ/hr

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 46


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Heat Exchanger
The design is modified to reduce the operating cost represented in
Chiller & Heater duties, by adding a Heat Exchanger before the Chiller
where the overhead from the inlet separator is pre-cooled by already
refrigerated gas from LTS.

Heat Exchanger Design Specifications:

- Sales Gas Temperature= 10oC


- Tube side Pressure drop=35kPa
- Shell side Pressure drop= 5kPa
- No heat losses inside the heat exchanger.
- Choose Weighted Exchanger as Model

Calculate the duty rejected from the chiller after this modification .
Calculate the Overall Heat Transfer Coefficient (UA) for the HX ..

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 47


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Solution:

1- Remove the heater, outlet stream and heater energy stream.


2- Disconnect the chiller inlet from the chiller (cooler).
3- Add a heat exchanger from the palette:

4- Open the heat exchanger and complete the required data:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 48


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Weighted. The heating curves are broken into intervals, which then
exchange energy individually. An LMTD and UA are calculated for
each interval in the heat curve and summed to calculate the overall
exchanger UA. The Weighted method is available only for
Counter-Current exchangers.

Endpoint. A single LMTD and UA are calculated from the inlet


and outlet conditions. For simple problems where there is no phase
change and Cp is relatively constant, this option may be sufficient.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 49


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

5- Open the chiller and re-connect the tube side outlet to the chiller inlet

The duty rejected from the chiller after this modification = 1.878 e6 kJ/hr
The Overall Heat Transfer Coefficient (UA) for the HX= 2.786 e5 kJ/C-h

Before Modification After Modification


Chiller Duty 4.186 *106 1.878 *106
Heater Duty 2.287 *106 0

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 50


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Adjust
Adjust the LTS feed temperature to ensure the LTS vapor rate of 1200
kgmole/hr using Adjust operation.
Calculate the temperature of LTS feed .

1- Select an adjust operation from the palette:

2- Open the adjust operation and select the adjusted variable (LTS
feed Temperature) and the Target variable (LTS Vapor molar flow).

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 51


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 52


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

You can see the total number of iterations from the monitor tab:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 53


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Propane Refrigeration
Loop

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 54


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Workshop
Refrigeration systems are commonly found in the natural gas
processing industry and in processes related to the petroleum
refining, petrochemical, and chemical industries. Refrigeration is
used to cool gas to meet a hydrocarbon dewpoint specification
and to produce a marketable liquid.
In this module you will construct, run, analyze and manipulate a
propane refrigeration loop simulation. You will convert the
completed simulation to a template, making it available to
connect to other simulations.

Learning Objectives
Once you have completed this module, you will be able to:

Add and connect operations to build a flowsheet.


Understand how to simulate the vapor compression loop.
Understand forward-backward information propagation in
HYSYS.
Using the spread sheet to calculate the COP (Coefficient Of
Performance) for the loop.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 55


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Example:

A Refrigeration cycle utilizes propane as the working fluid is used in


the liquefaction of the NG. Propane is fed to an evaporator (Heater) the
pressure drop=5 kPa, where it absorbed 1.50e+6 kJ/hr from the NG and
leaves at the dew point (Vapor Fraction=1.0) at T= -15oC. The output of
the evaporator is then compressed adiabatically with efficiency of 75%,
and then it's condensed to reject heat. Inside the Condenser there is a
pressure drop of 30 kPa, and leaves as saturated liquid at 45oC. Finally, the
propane passes through a valve to return the pressure of the Evaporator.

Fluid Pkg: Peng Robinson

Calculate:

Pressure of the evaporator fed in kPa.

Flow rate of propane in kmol/hr.

Valve pressure drop in kPa.

Temperature of the valve outlet in oC.

Compressor duty in hp.

Condenser duty in kJ/hr.

* Calculate the COP (Coefficient of Performance) for the cycle

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 56


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

To start the program, From Start Menu, Select All Programs >>
Aspen Tech >> Process Modeling V8.3 >>>> Aspen HYSYS >>
Aspen HYSYS

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 57


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

1- First, Start a new case

2- Add the Components

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 58


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

3- Choose the system components from the databank:

Now, select the suitable fluid package

In this case, select Peng-Robinson

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 59


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now you can start drawing the flow sheet for the process by clicking the
Simulation button:

Now add a material stream to define the composition and the conditions
of the feed stream
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 60
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

From the palette:

Add the mole fraction for the inlet stream (Propane =1)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 61


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Then leave the stream not solved till the loop is closed

Add the evaporator (heater)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 62


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Complete the connections and then go to parameters page to add the


pressure drop and the duty rejected

Go to stream 2 and complete the vapor fraction & temperature

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 63


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Then add a compressor to raise the pressure of the vapor out from the
heater

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 64


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Then go to parameters to make sure that the adiabatic efficiency is 75%

Leave the compressor not solved till the loop is closed then add a cooler

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 65


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Complete the connections and then go to parameters page to add the


pressure drop =30 kPa

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 66


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Go to stream 4 and complete the vapor fraction (Saturated liquid=0.0) &


temperature (45oC)

Then add a valve to close the loop

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 67


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

You can adjust the Flowsheet and rotate the streams and equipment from
the above menu (Flowsheet/Modify)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 68


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Results:

Pressure of the evaporator fed in kPa. 296.1

Flow rate of propane in kmol/hr. 146.4

Valve pressure drop in kPa. 1243.34

Temperature of the valve outlet in oC. -14.51

Compressor duty in hp. 252.8

Condenser duty in kJ/hr. 2.179 e+6

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 69


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Coefficient of Performance (COP)

Is a measure of the efficiency of a refrigeration cycle is the coefficient of


performance, COP
It is the ratio of desired output divided by the required input.
In the vapor-compression system, the net power input is equal to the
compressor power, since the expansion valve involves no power input or
output.
COP= Evaporator Duty/ Compressor Power

We can use the spreadsheet operation in HYSYS to calculate the COP of the
cycle:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 70


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now we can calculate the COP by importing the two variables;


Evaporator duty & Compressor power

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 71


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Right click on the cell B1 and select import variable to import the duty of
the evaporator

Right click on the cell B2 and select import variable to import the power
of the Compressor

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 72


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Note that the 2 variables must be in the same units (kJ/hr or KW)

Now, divide the two variables in the cells b1 & b2 to calculate the COP in
b3

The result will be 2.2

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 73


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Challenge:

Now change the duty of the evaporator to 3 e6 kJ/hr (in the evaporator not
in the spreadsheet), then open the spreadsheet to calculate the COP &
explain the results.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 74


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Distillation Column 4

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 75


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Workshop
Separation of light products is present in any Hydrocarbons
operations. In this module, a column will be modeled to separate
Light and heavy components from each other using a distillation
column with 12 trays.

Learning Objectives
Once you have completed this section, you will be able to:

Add columns using the Input Experts.


Add extra specifications to columns.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 76


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Example:

We need to separate a mixture of five paraffins into light and heavy fraction
by using a distillation column with 12 trays, a full reflux condenser, and a
Kettle reboiler.

The feed stream (1000 lbmol/hr) consists of 3% (mole %) ethane, 20%


propane, 37% n-butane, 35% n-pentane and 5% n-hexane at 225 oF and
250 psia, which enters the column on the sixth tray, counting from the top.
The condenser and reboiler pressures are 248 and 252 psia, respectively.
The preliminary design specifications require a reflux ratio of 6.06 and a
vapor overhead product of 226 lbmol/hr. Subsequently, the design is
modified to ensure propane overhead flow of 191 lb mol/hr and n-butane
bottom flow of 365 lbmol/hr.

Use SRK Fluid Pkg

Calculate:

The Condenser, the Reboiler Temperatures & the Reflux Ratio after
modification

Condenser Temp oC
Reboiler Temp oC
Reflux Ratio

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 77


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

To start the program, From Start Menu, Select All Programs >>
Aspen Tech >> Process Modeling V8.3 >>>> Aspen HYSYS >>
Aspen HYSYS

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 78


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

7- First, Start a new case

8- Add the Components

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 79


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

9- Choose the system components from the databank:

Now, select the suitable fluid package

In this case, select SRK

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 80


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now you can start drawing the flow sheet for the process by clicking the
Simulation button:

Now add a material stream to define the composition and the conditions
of the feed stream

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 81


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

From the palette:

Add the mole fraction for the inlet stream

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 82


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Then go to the conditions page to complete the feed stream conditions:

Add a distillation tower (with condenser & Reboiler):

Now, start building the column:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 83


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Select Regular Hysys Reboiler in the reboiler configuration page for Kettle
Reboiler as follows:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 84


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The target is to run the column with 2 specifications:

1- Reflux Ratio = 6.06

2- Overhead vapor rate (Vent rate) =226 lbmole/hr

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 85


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The column statues bar (Red bar) is now unconverged till clicking the RUN
button to converge the column.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 86


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Let's go to the monitor page and see the current specifications:

We must make 2 specifications active to make the DOF=0.0 and to


converge the column.

The two specifications are the target that you want to achieve from the
column.

Although the column is converged, it is not always practical to have vapor


rate & reflux ratio specifications. These specifications can result in
columns which cannot be converged or that produce product streams with
undesirable properties if the column feed conditions change.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 87


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

An alternative approach is to specify either component fractions or


component flow rates for the column product streams.
Now we have to give the column another 2 new specifications to run with
(more practical)
1- Propane overhead flow of 191 lbmol/hr
2- Butane bottom flow of 365 lbmol/hr.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 88


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the other specification:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 89


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

You can change the specifications by marking the Active check box on the
2 new specifications

The Results is always inside the performance page:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 90


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Go to column profile to see the temperature & Pressure profile across the
tower.

Condenser Temp 46 oC
Reboiler Temp 128.8 oC
Reflux Ratio 8.54

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 91


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Oil Characterization

5
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 92
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Workshop
The petroleum characterization method in HYSYS will convert laboratory
analyses of condensates, crude oils, petroleum cuts and coaltar liquids into
a series of discrete hypothetical components. These petroleum hypo
components provide the basis for the property package to predict the
remaining thermodynamic and transport properties necessary for fluid
modeling.
HYSYS will produce a complete set of physical and critical properties for
the petroleum hypo components with a minimal amount of information.
However, the more information you can supply about the fluid, the more
accurate these properties will be, and the better HYSYS will predict the
fluid's actual behavior.
In this example, the Oil Characterization option in HYSYS is used to model
a crude oil. The crude is the feed stock to a Pre-heat Train, followed by the
Atmospheric Crude Column, which will be modelled in a subsequent
module.

Learning Objectives
Once you have completed, you will be able to use the Oil Characterization
option in HYSYS.

Oil Characterization

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 93


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The petroleum characterization method in HYSYS will convert laboratory analyses


of condensates, crude oils, petroleum cuts and coal-tar liquids into a series of
discrete hypothetical components. These petroleum hypocomponents provide the
basis for the property package to predict the remaining thermodynamic and
transport properties necessary for fluid modeling.
In this example, the Oil Characterization option in HYSYS is used to model a
crude oil. The crude is the feed stock to oil refining process. (FPkg=PR)
Bulk Properties of the crude:
API Gravity of 29 for the crude
Light Ends (Liquid Volume):
Light Ends Liquid Vol %
Methane 0.0065

Ethane 0.0225

Propane 0.3200

i-butane 0.2400

n-butane 1.7500

i-pentane 1.6500

n-pentane 2.2500

TBP distillation data (Liquid Volume %):


Assay Percent Temperature (oC)
0 -12
4 32
9 74
14 116
20 154
30 224
40 273
50 327
60 393
70 450
76 490
80 516

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 94


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

To start the program, From Start Menu, Select All Programs >>
Aspen Tech >> Process Modeling V8.0 >>>> Aspen HYSYS >>
Aspen HYSYS

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 95


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

1- First, Start a new case

2- Add the Components

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 96


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

3- Choose the system components from the databank:


4- First we should add the pure components first (Light Ends)

Light Ends are defined as pure components with low boiling points.
Components in the boiling range of C1 to n-C5 are most commonly of
interest.

Add the pure components (C1, C2, C3, n-C4, i-C4, n-C5, i-C5, H2O)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 97


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now, select the suitable fluid package

In this case, select Peng-Robinson

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 98


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Characterize the Assay


The assay contains all of the petroleum laboratory data, boiling point
curves, light ends, property curves and bulk properties. HYSYS uses the
supplied Assay data to generate internal TBP, molecular weight, density
and viscosity curves, referred to as Working Curves.
To characterize the assay follow the following steps:
1- Go to Oil Manager.

2- Click on Input Assay & then Click Add button:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 99


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Bulk Properties
Bulk Properties for the sample may also be supplied. The bulk properties
are optional if a distillation curve or chromatograph have been supplied
Change the bulk properties from Not used to Used and add the value for
standard Density = 29 API_60
Note:
141.5
API = 131.5

Select the Assay Data Type >> TBP

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 100


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Select the Distillation radio button in the Input Data group box.
Select the Assay Basis as Liquid Volume (use the drop-down menu).
Click the Edit Assay button; this will allow you to enter the assay
information below.

Add the assay data:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 101


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Use the drop-down lists to select Input Composition for Light Ends

Select the Light Ends radio button and enter the data given from Input
Data

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 102


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Once you have entered all of the data, click the Calculate button. The status
message at the bottom of the Assay view will display Assay Was Calculated.

Once the Assay is calculated, the working curves are displayed on the Plots and
Working C u r v e s tabs. The working curves are regressed and extrapolated
from the Assay input. From the user-supplied data, HYSYS generates curves
for NBP, molecular weight, mass density, and viscosity. These working curves
are used in determining the properties of the hypo components generated in
the Blend step.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 103


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The Output Blend characterization in HYSYS splits the internal working curves
for one or more assays into hypo components. The Blend tab of the Oil
Characterization view provides two functions, cutting the Oil into Hypo
components and Blending two or more Assays into one set of hypo
components.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 104


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 105


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The results of the calculation can be viewed on the Tables tab

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 106


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The final step of the characterization is to transfer the hypo


component information into the Flowsheet.

In the Stream Name column, enter the name Raw Crude to which the oil
composition will be transferred.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 107


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

HYSYS will assign the composition of your calculated Oil and Light Ends
into this stream, completing the characterization process.
Now you can return to the Simulation environment to see the stream (Raw
Crude) with a full composition:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 108


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Save Your Case!

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 109


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Atmospheric Distillation

6
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 110
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Workshop
Atmospheric Crude Columns are one of the most important pieces of
equipment in the petroleum refining industry. Typically located after the
Desalter and the Crude Furnace, the Atmospheric Tower serves to distil
the crude oil into several different cuts. These include naphtha, kerosene,
light diesel, heavy diesel and AGO.
In this module, you will construct, run, analyze and manipulate an
Atmospheric Crude Column simulation. You will begin by building a
simple column and continue by adding side operations to the column.

Learning Objectives
Build and converge an Atmospheric Crude Column.
Use HYSYS to analyze and predict the behavior of a simulated
column.
Add side operations to a column to improve operation and
efficiency.
Add cut point specifications to increase side product quality and
quantity.

Pre-Heat Train
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 111
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

A crude stream at 15oC, 1000 kPa and flowrate of 6105 kg/hr is mixed
with a stream of water at 15oC, 1000 kPa and flowrate of 21600 kg/hr
using a Mixer, the outlet from the mixer is then heated to 65oC through a
Heater (p=50 kPa), the heater outlet is fed to the tube side of a Shell &
Tube Heat Exchanger, where it's heated using a Shell inlet stream having
the same composition as the crude feed stream and enters the shell of the
heat exchanger at 180oC, 200 kPa and flowrate of 175m3/hr. The pressure
drops for the Tube and Shell sides, will be 35 kPa and 5 kPa, respectively.
The tube outlet from the HX is then sent to a desalter which is simply
modeled as Three Phase Separator where desalted water, oil and gas is
separated. The oil stream (light liquid) from the desalter is then heated to
175oC through a Heater (Pressure drop=375 kPa) and then sent to a
Preflash (Separator) to reduce the light components in the feed. The liquid
product from the separator is then heated to 400oC inside a Heater (Pressure
drop=250 kPa) before entering the Atmospheric Column.

Heat Exchanger Specification:


- Use Simple weighted model
- Min Approach = 30C (54F). This is the minimum temperature
difference between the hot and the cold stream.

Calculate:
- The vapor fraction of the product stream before entering the
Atmospheric column.
- The Shell side outlet Temperature.
- The vapor molar flow rate from the Preflash.

Atmospheric Distillation

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 112


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

A feed stream from the pre-heat train is fed to the 28th tray of a Refluxed
Absorber with 29 trays and a partial condenser to separate Off Gases,
Naphtha and Bottom Residue. A steam stream (vapor fraction =1.0,
pressure =1380 kPa and flowrate=3400 kg/hr) is fed to the bottom of the
tower to provide the necessary heat. A water draw stream is required to
remove the condensed steam from the overhead condenser. The tower is
operated with the following conditions:

Condenser Pressure 140 kPa Condenser Temperature 40 oC

Condenser Pressure Drop 60 kPa Top Stage Temperature 120 oC

Bottom Stage Pressure 230 kPa Bottom Stage Temperature 340 oC

Specifications:
Overhead vapor rate 0.0 kgmole/hr

Distillate rate (Naphtha rate) ..

What is the flow rate of?


Naphtha _______________ Residue ____________________
Wastewater ____________

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 113


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Side Strippers & Pump Arounds


Side Strippers are added to the column in order to improve the quality of
the three main products (Kerosene, Diesel, and AGO). There are two types
of side strippers available in HYSYS: Reboiled and Steam Stripped. We
will install one reboiled side stripper and two steam stripped.

AGO SS Diesel SS Kerosene SS


Draw Stage 22 17 9
Return Stage 21 16 8
Configuration Steam Stripped Steam Stripped Reboiled
Product flow . . .

Temperature Pressure Flowrate


AGO Steam 150 oC 350 kPa 1150 kg/hr
Diesel Steam 150 oC 350 kPa 1350 kg/hr

Pump Arounds help to improve the columns efficiency. They operate by


drawing a liquid stream from one stage cooling it, and pumping it into a
higher stage. In effect, this process adds to the reflux between these two
stages.

AGO PA Diesel PA Kerosene PA


Draw Stage 22 17 9
Return Stage 21 16 8
Flowrate 200 m3/h 200 m3/h 330 m3/h
Duty -3.7e7 kJ/h -3.7e7 kJ/h -4.5e7 kJ/h

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 114


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Load your Pre-Heat Train case from the Pre-Heat Train


module.

Add a steam stream to provide the heating effect to the bottom of the
tower instead of using a reboiler:

Vapor fraction =1.0, pressure =1380 kPa and flowrate=3400 kg/hr

Composition (100% water)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 115


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Adding the Atmospheric Column


The atmospheric column is modeled as a refluxed absorber,
- Double-click on the Refluxed Absorber icon on the Object Palette.

The tower (29 trays) is operated with the following conditions:

Condenser Pressure 140 kPa Condenser Temperature 40 oC

Condenser Pressure Drop 60 kPa Top Stage Temperature 120 oC

Bottom Stage Pressure 230 kPa Bottom Stage Temperature 340 oC

Specifications:
Overhead vapor rate 0.0 kgmole/hr
Distillate rate (Naphtha rate) 0.153 681.9 m3/hr = 104.3 m3/hr

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 116


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The Water Draw checkbox must be checked to prevent two liquid


phases being formed in the column.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 117


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 118


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Run the column

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 119


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Adding Side Strippers


Side Strippers are added to the column in order to improve the quality of
the three main products (Kerosene, Diesel, and AGO). There are two types
of side strippers available in HYSYS: Reboiled and Steam Stripped. We
will install one reboiled side stripper and two steam stripped.

AGO SS Diesel SS Kerosene SS

Draw Stage 22 17 9

Return Stage 21 16 8

Configuration Steam Stripped Steam Stripped Reboiled

Product flow 0.045 681.9 m3/hr (0.102+0.087) 681.9 0.094 681.9 m3/hr

= 30.69 m3/hr = 128.88 m3/hr = 64.1 m3/hr

Temperature Pressure Flowrate

AGO Steam 150 oC 350 kPa 1150 kg/hr

Diesel Steam 150 oC 350 kPa 1350 kg/hr

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 120


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

First we need to add two steam streams to provide the heating effect for
both AGO & Diesel Side Strippers
Temperature Pressure Flowrate
AGO Steam 150 oC 350 kPa 1150 kg/hr
Diesel Steam 150 oC 350 kPa 1350 kg/hr

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 121


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Go to the Side Ops tab inside the atmospheric tower to add the three side
stripers:

First add the AGO Side Stripper

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 122


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Close the window and run the column


Make sure that the column is converged

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 123


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the Diesel Side stripper:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 124


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Close the window and run the column


Make sure that the column is converged

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 125


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the Kerosene Side stripper:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 126


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Close the window and run the column


Make sure that the column is converged

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 127


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Adding Pump Arounds


Pump Arounds help to improve the columns efficiency. They operate by
drawing a liquid stream from one stage cooling it, and pumping it into a
higher stage. In effect, this process adds to the reflux between these two
stages.

AGO PA Diesel PA Kerosene PA


Draw Stage 22 17 9
Return Stage 21 16 8
Flowrate 200 m3/h 200 m3/h 330 m3/h
Duty -3.7e7 kJ/h -3.7e7 kJ/h -4.5e7 kJ/h

Go to the Side Ops tab inside the atmospheric tower to add the three Pump
Arounds:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 128


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the AGO Pump Around (PA)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 129


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Close the window and run the column


Make sure that the column is converged

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 130


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the Diesel Pump Around

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 131


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Close the window and run the column


Make sure that the column is converged
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 132
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the Kerosene Pump Around

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 133


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 134


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Close the window and run the column


Make sure that the column is converged

You can find the detailed flow sheet by entering the Column
Environment

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 135


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 136


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

To return to the main environment:

Save Your Case!

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 137


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Optimization
Optimization

Economical Production

Max.
Max. Profit Min. Cost
Productivity

7
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 138
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Workshop
In this example, a simple distillation column to separate Tetrahydrofuran

(THF) from Toluene is simulated. The object of the exercise is to select

the product specifications such that profit is maximized. A special tool in

HYSYS, the Optimizer, will be used to find the optimum operating

conditions.

HYSYS includes additional modelling and decision support tools that can

be used to enhance the usability of your models. In this module, you will

use the HYSYS optimization tool available in HYSYS to investigate the

debottlenecking and optimization of a crude column.

Learning Objectives
Once you have completed this section, you will be able to:

Use the Optimizer tool in HYSYS to optimize flowsheets

Use the Spreadsheet to perform calculations

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 139


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Example:

3700 kg/hr mixture of tetrahydrofuran & toluene (44 mass% THF) at 10oC
and 140 kPa is to be separated by distillation to get each of them with
purity of 99.5 mass% of THF & 94 mass% of Toluene (THF is the more
volatile component).
Use Wilson fluid package
The column specifications are:
The condenser & reboiler pressure are 103 kPa & 107 kPa.
The condenser works on total condensation conditions.
Number of stages = 10.
Feed enters from the 5th tray.
Calculate:
The reflux ratio and the distillate rate under the specified
conditions.
Reflux Ratio
Distillate Rate kgmol/hr
Data:
Feed price= 0.05 $/kg.
Pure toluene selling price= 0.136 $/kg
Pure THF selling price= 0.333 $/ kg
Cooling Cost= 0.471 $/ kw.hr
Heating Cost= 0.737 $/kw.hr
Note:
Profit = (Total Toluene selling price + Total THF selling price) - (Feed
cost + Heating cost + Cooling Cost)
Use a range of 0.99 to 0.999 for THF limit & 0.9 to 0.99 for the
toluene.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 140


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

To start the program, From Start Menu, Select All Programs >>
Aspen Tech >> Process Modeling V8.0 >>>> Aspen HYSYS >>
Aspen HYSYS

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 141


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

5- First, Start a new case

6- Add the Components

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 142


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

7- Choose the system components from the databank:

Now, select the suitable fluid package

In this case, select Wilson

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 143


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now you can start drawing the flow sheet for the process by clicking the
Simulation button:

Now add a material stream to define the composition and the conditions
of the feed stream

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 144


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

From the palette:

Add a distillation tower:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 145


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 146


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 147


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 148


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 149


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 150


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Optimization
We need to check if the operating conditions are optimum or not.

The Variables to check are: THF Purity & Toluene Purity

Using the Optimizer tool:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 151


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

And do the same steps to add the other variable

Use a range of 0.99 to 0.999 for THF limit & 0.9 to 0.99 for the toluene.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 152


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now we have to start building the profit module using the spreadsheet
operation:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 153


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Profit= Income - Cost


Profit = (Total Toluene selling price + Total THF selling price) - (Feed
cost + Heating cost + Cooling Cost)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 154


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 155


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The profit formula will be in D8:

= (d3*b3*b4+d5*b5*b6)-(d1*b1+d2*b2+d7*b7)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 156


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now you can go to the monitor tab inside the column to see the
optimum values for the THF & Toluene purities.

Save Your Case!


By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 157
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Gas Gathering

8
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 158
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Workshop
In this example, a gas gathering system located on varied terrain is
simulated using the steady state capabilities of HYSYS. The following
figure shows the physical configuration of this system superimposed on a
topographic map. The system consists of four wells distributed over an
area of approximately 2.0 square km, connected to a gas plant via a
network of pipelines.

Learning Objectives
Once you have completed this module, you will be able to use the Pipe
Segment in HYSYS to model pipelines.

Example:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 159


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

There are 4 gas wells, we need to gather the gas from the wells and
transfer it to the plant through pipe lines shown below:

The composition of the four wells is the same:


Component Mole Fraction Component Mole Fraction
Methane 0.6230 n-pentane 0.00405
Ethane 0.2800 n-hexane 0.00659
Propane 0.0163 C7+ 0.00992
i-butane 0.00433 N2 0.00554
n-butane 0.00821 CO2 0.0225
i-pentane 0.00416 H2S 0.0154
C7+: MW=122, =47.45 lb/ft3

The pipe segments data are given below:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 160


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Schedule 40 steel pipes is used throughout and all branches are buried at
a depth of 1 m (3 ft). All pipes are uninsulated
Consider inner and outer HTC and the pipe wall in heat transfer
estimation. (Ambient Temperature=5oC)
- Calculate the pressure drop and the heat loses inside each branch.
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 161
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

To start the program, From Start Menu, Select All Programs >>
Aspen Tech >> Process Modeling V8.x >>>> Aspen HYSYS >>
Aspen HYSYS

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 162


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

8- First, Start a new case

9- Add the Components

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 163


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

10- Choose the system components from the databank:

After adding the pure components (N2, H2S, CO2, C1, C2, C3, n-C4, i-C4,
n-C5, i-C5, n-C6, H2O) we have to add the last component (C7+) which is
not a pure component as it represents all components above C7 including
C7 in the feed.
To define C7+ we have to create it as a hypothetical component as the
following:
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 164
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

From the drop menu select Hypothetical instead of pure components

Select create and edit hypos

Click on New Hypo

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 165


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

After adding a hypo component you can edit the name, add the properties
you have, and estimate the unknown properties as follows:

Finally add the hypo component to the component list

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 166


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now, select the suitable fluid package

In this case, select Peng-Robinson

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 167


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now you can start drawing the flow sheet for the process by clicking the
Simulation button:

Now add a material stream to define the composition and the conditions
of the feed stream
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 168
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

From the palette:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 169


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

After adding the compositions and the conditions for the first well, add
another stream for well 2 and define the composition from the first stream
as follows:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 170


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the conditions for the second stream

Add the conditions & Compositions for the other two streams as
above

Now, Add a Pipe Segment from the palette

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 171


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The pipe segment is used to simulate a wide variety of piping situations


ranging from single/multiphase plant piping with rigorous heat transfer
estimation, to large capacity looped pipeline problems

On the Sizing page, you construct the length-elevation profile for the Pipe
Segment. Each pipe section and fitting is labeled as a segment. To fully
define the pipe sections segments, you must also specify pipe schedule,
diameters, pipe material and a number of increments.
- The first pipe, Branch 1 is broken into three segments.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 172


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

- Add the first segment to the pipe unit operation by clicking the Append Segment
button. Specify the following information for the segment.
- To specify the diameter, click the View Segment button.

- Select Schedule 40 as the Pipe Schedule.


- From the Available Nominal Diameters group, select 76.20 mm (3 inch) diameter
pipe and click the Specify button. The Outer and Inner Diameter will be calculated by
HYSYS.
- Use the default Pipe Material, Mild Steel

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 173


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

- Two more segments are needed to complete the branch.

The Pipe Segment is not yet able to solve because we have not specified
any information about the heat transfer properties of the pipe.

Heat Transfer page


On this page, you select the method that HYSYS will use for the heat transfer
calculations.

For all pipes in this simulation, use the Estimate HTC method.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 174


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now add the remaining unit operations to your case.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 175


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 176


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 177


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now, add a mixer operation to mix the outlet streams from both
branch 1 & branch 2

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 178


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 179


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 180


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 181


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 182


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 183


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 184


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Mix the outlet from both branch 5 & branch 6

The last branch

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 185


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 186


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 187


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

You can go to the performance tab inside each segment to view the
profile

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 188


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

You can also go to the parameters page to see the pressure drop &
heat losses inside each branch:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 189


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Save Your Case!

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 190


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

NGL Fractionation

9
By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 191
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Workshop
Recovery of natural-gas liquids (NGL) from natural gas is quite common
in natural gas processing. Recovery is usually done to:
- Produce transportable gas (free from heavier hydrocarbons which
may condense in the pipeline).
- Meet a sales gas specification.
- Maximize liquid recovery (when liquid products are more valuable
than gas).
Aspen HYSYS can model a wide range of different column configurations.
In this simulation, an NGL Plant will be constructed, consisting of three
columns:
De-Methanizer (operated and modeled as a Reboiled Absorber column)
De-Ethanizer (Distillation column)
De-Propanizer (Distillation column)

Learning Objectives
Once you have completed this section, you will be able to:
Add columns using the Input Experts.
Add extra specifications to columns.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 192


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

NGL Fractionation Train


It's required to process a crude natural gas to remove the heavier hydrocarbons from it
thus the composition of it would be suitable for transportation by passing the crude gas
which comes from two different wells to three towers: De-Methanizer, De-Ethanizer
and De-Propanizer.
The first well at (-140 oF, 330 psia and flow rate of 3575 lbmol/hr) have the following
conditions and compositions: (Fluid Package: Peng Robinson)
Component Mol frac Component Mol frac
N2 0.0025 n-C4 0.0085
CO2 0.0048 i-C5 0.0036
C1 0.7041 n-C5 0.002
C2 0.1921 n-C6 0.0003
C3 0.0706 n-C7 0.0002
i-C4 0.0112 n-C8 0.0001
o
The second one at (-120 F, 332 psia and flow rate of 475 lbmol/hr) have the following
conditions and composition

Component Mol frac Component Mol frac


N2 0.0057 n-C4 0.0197
CO2 0.0029 i-C5 0.0147
C1 0.7227 n-C5 0.0102
C2 0.1176 n-C6 0.0037
C3 0.075 n-C7 0.0047
i-C4 0.0204 n-C8 0.0027
There's also an energy supplied to the De-Methanizer of (2e6 BTU/hr) which is used to
improve the efficiency of the separation.
The De-Methanizer (reboiled absorber) has the following specifications:
- Feed 1 Material Stream enters the column from the top stage inlet
- Feed 2 Material stream enters from the 2nd stage
- Ex-duty Energy Stream enters from the 4th stage
- Number of stages = 10
- Top Stage pressure = 330 psia & Reboiler pressure = 335 psia
- Top Stage temperature = -125oF & Reboiler temperature = 80 oF
- Ovhd Prod Rate = 2950 lbmole/hr (1338 Kg/hr)
After running the column with the above specifications, the design is
then modified to ensure that the overhead molar fraction of the
methane is 0.96

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 193


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Most of methane is removed from the top of the tower and the bottom
stream is pumped to 2790 kpa then it enters to the De-Ethanizer (distillation
Column) where most of the ethane in the crude is taken as an overhead
product then it is processed to use in different applications.

The de-ethanizer has the following specifications:

After running the column with the above specifications, the design is
modified to ensure that the bottom stream has ratio between C2/C3 =
0.01

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 194


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Then the bottom product is sent to a valve where the pressure of it decrease
to 1690 kpa, the outlet flow from the valve is sent to a de-propanizer
(distillation Column) where most of propane is removed from the top and
the heavier hydrocarbons is removed from the bottom

The specifications of the de-propanizer are:

After running the column with the above specifications, the design is
modified to ensure that the overhead molar fraction of the i-C4 & n-
C4 =0.15 AND propane bottom product molar fraction = 0.02

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 195


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

To start the program, From Start Menu, Select All Programs >>
Aspen Tech >> Process Modeling V8.x >>>> Aspen HYSYS >>
Aspen HYSYS

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 196


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

11- First, Start a new case

12- Add the Components

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 197


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

13- Choose the system components from the databank:

After adding the pure components (N2, CO2, C1, C2, C3, n-C4, i-C4, n-
C5, i-C5, n-C6, C7, C8)

Now, select the suitable fluid package

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 198


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

In this case, select Peng-Robinson

Now you can start drawing the flow sheet for the process by clicking the
Simulation button:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 199


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now add a material stream to define the composition and the conditions
of the feed stream

From the palette:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 200


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

After adding the compositions and the conditions for the first stream, add
another stream for feed 2:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 201


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Part 1: De- Methanizer Column


The De-Methanizer is modeled as a reboiled absorber operation, with two feed streams
and an energy stream feed, which represents a side heater on the column.
- Add an Energy stream with the duty = 2.1 e6 kJ/hr
- Double-click on the Reboiled Absorber icon on the Object Palette.

De-Methanizer Specs:
- Feed 1 Material Stream enters the column from the top stage inlet
- Feed 2 Material stream enters from the 2nd stage
- Ex-duty Energy Stream enters from the 4th stage
- Number of stages = 10
- Top Stage pressure = 330 psia
- Reboiler pressure = 335 psia
- Top Stage temperature = -125oF
- Reboiler temperature = 80 oF
- Ovhd Prod Rate = 2950 lbmole/hr (1338 Kg/hr)
- C1 fraction in the Ovhd stream = 0.96

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 202


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 203


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 204


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Although the column is converged, it is not always practical to have


flow rate specifications. These specifications can result in columns
which cannot be converged or that produce product streams with
undesirable properties if the column feed conditions change.

An alternative approach is to specify either component fractions or


component recoveries for the column product streams.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 205


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Run the column:

After running the column, add a pump to transfer the bottom liquid to the
De-ethanizer:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 206


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The pump outlet pressure is 2790 kPa (from Worksheet)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 207


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Part 2: De- Ethanizer Column


The outlet from the pump is then fed to the de-ethanizer:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 208


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 209


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the Column component ratio from the monitor page as follows:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 210


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 211


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add a valve on the bottom liquid stream:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 212


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Outlet pressure from the valve = 1690 kPa (from the Worksheet tab)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 213


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Part 3: De- Propanizer Column


Add a distillation column (De-propanizer):

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 214


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 215


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now, let's add a new 2 specifications instead of the current:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 216


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

After running the column, you can view the results from the Performance
page (for any column)

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 217


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 218


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Save Your Case!


By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 219
Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 220


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Oil
Stabilization
Optimization

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 221


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Workshop
A poor-boy stabilization scheme is used to separate an oil and gas mixture
into a stabilized oil and a saleable gas. A simple three-stage separation with
heating between each stage is used and the object of the exercise is to select
the let-down pressure and temperatures such that the products revenue less
the utilities cost is maximized. A special tool in HYSYS, the Optimizer,
will be used to find the optimum operating conditions.
HYSYS includes additional modelling and decision support tools that can
be used to enhance the usability of your models. In this module, you will
use the HYSYS optimization tool available in HYSYS to investigate the
debottlenecking and optimization of a crude column.

Learning Objectives
Once you have completed this section, you will be able to:

Use the Optimizer tool in HYSYS to optimize flowsheets

Use the Spreadsheet to perform calculations

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 222


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Oil Stabilization
A feed stream @ 10oC, 4125 kPa with a flowrate of 1 MMSCFD is fed to a
heater (duty=4.25*105 kJ/hr) before entering the first separator where
the separated liquid is heated in a second heater (duty=3.15*105 kJ/hr).
The outlet from the heater is then sent to a letdown valve in order to
decrease the pressure to 2050 kPa before entering the second separator
where the separated liquid is heated through a third heater
(duty=1.13*105 kJ/hr). The outlet from the third heater is then throttled
through a valve (outlet pressure = 350 kPa) and then fed to a third
separator to obtain the final liquid oil product.
Each gas stream from the 2nd & 3rd separators is fed to a separate
compressor to raise the pressure to 4125 kPa and then mixed (using a
mixer) with the gas stream from the 1st separator to get the final gas
product stream.
Notes:
- Pressure drop across all heaters and separators are 0.0.
Comp Mol frac Comp Mol frac
C1 0. 316 n-C5 0.053
C2 0.158 C6 0.027
C3 0.105 C7 0.026
i-C4 0.105 C8 0.026
n-C4 0.105 C9 0.026
i-C5 0.053
Calculate:
- The total liquid product = barrel/hr
- The total gas product = m3_gas/hr

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 223


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Oil Stabilization Optimization


In this case, we want to maximize the total operating profit while
achieving an RVP of Liquid Product less than 96.5 kPa. The incomes from
the Plant are both the Gas and Liquid Products. The operating costs are
the Steam Costs for each Heater plus the Power Cost for each
Compressor.
Profit = Income - Cost
Profit= (Gas Product + Liquid Product) (Steam Costs + Compression Cost)

Prices & costs:


Oil Price= 15 $/bbl
Gas Price =0.106 $/m3_gas

Steam Cost= 0.682 $/kW-h

Compression Cost=0.1 $/kW-h

The variables to be adjusted:


- Heater duties (for the 3 heaters). Use range of 0 1e6 kJ/hr
- Valves outlet pressures.
- Use range of 650 3500 kPa for the first valve
- Use range of 70 1000 kPa for the second valve

Calculate:

- The optimum values for the adjusted variables


- The maximum profit .. $/hr

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 224


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

To start the program, From Start Menu, Select All Programs >>
Aspen Tech >> Process Modeling V8 >>>> Aspen HYSYS >>
Aspen HYSYS

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 225


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

10- First, Start a new case

11- Add the Components

12- Choose the system components from the databank:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 226


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now, select the suitable fluid package

In this case, select Peng-Robinson

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 227


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Now you can start drawing the flow sheet for the process by clicking the
Simulation button:

Now add a material stream to define the feed stream composition and
conditions

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 228


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

From the palette:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 229


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add a heater with a duty of 4.25 * 105 kJ/hr and pressure drop of 0.0

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 230


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the first separator

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 231


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The liquid stream is then heated, add a second heater with a pressure
drop of 0.0 & duty of 3.15 * 105

Add a valve with outlet pressure of 2050 kPa

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 232


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add the second separator

The liquid from the second separator is now fed to a third heater with a
pressure drop of 0.0 & duty of 1.13 * 105

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 233


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add a second valve with an outlet pressure of 350 kPa

Add the third separator

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 234


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The vapor from the second separator is fed to a compressor to raise the
pressure to 4125 kPa

Add a compressor from the palette

The vapor from the third separator is fed to a second compressor to raise the
pressure to 4125 kPa

Add a second compressor with an outlet pressure of 4125kPa

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 235


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The three vapor streams will be mixed using a mixer

The RVP of the Liquid Product stream should be about 96.5 kPa to satisfy the
pipeline criterion.

Use cold properties analysis to see the current Reid Vapor Pressure for the
liquid product from the third separator:

From the attachments tab, select Analysis and then Create:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 236


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 237


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Changing the Units

We need to change the default unit set to fit this case

Change the units as follows:

Molar flow: m3_gas/hr

Liq. Vol. Flow: barrel/hr

Std. Vol. Flow: barrel/hr

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 238


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Optimization
HYSYS contains a multi-variable Steady State Optimizer. Once your flowsheet has
been built and converged, you can use the Optimizer tool to find the operating
conditions which minimize or maximize an Objective Function. The Optimizer owns
its own Spreadsheet for defining the Objective Functions as well as any constraint
expressions to be used. This allows you to construct Objective Functions which
maximize profit, minimize utilities or minimize exchanger UA.

In this case, we want to maximize the total operating profit while achieving an RVP
of Liquid Product less than 96.5 kPa. The incomes from the Plant are both the Gas
and Liquid Products. The operating costs are the Steam Costs for each Heater plus
the Power Cost for each Compressor.
Profit = Income - Cost
Profit= (Gas Product + Liquid Product) (Steam Costs + Compression Cost)

Use the Optimizer tool:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 239


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The variables to be optimized in order to maximize the profit should be


added now, these variables are:

The 3 Heaters duties and Valves outlet pressures

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 240


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

After adding all the 5 variables, set the upper and lower ranges for each
variable as follows:

The Optimizer has its own Spreadsheet for defining the Objective and
Constraint functions.

Now we have to start building the profit module using the spreadsheet
operation:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 241


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Profit= Income - Cost


Profit= (Gas Product + Liquid Product) (Steam Costs + Compression Cost)

Prices & costs:


Oil Price= 15 $/bbl
Gas Price =0.106 $/m3_gas

Steam Cost= 0.682 $/kW-h

Compression Cost=0.1 $/kW-h

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 242


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The RVP spec for the liquid should be added in the spread sheet in order to use it
as a constraint.

RVP spec= 96.5 kPa

First we need to increase the number of rows in the spread sheet to be 20 from
the parameters tab:

Now return to the spreadsheet tab again and add all the profit equation
parameters & variables.

After adding the labels, import the variables in each labeled cell:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 243


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Add all duties for heaters & compressors the same way as we did in the
previous step.

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 244


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Do the same for Oil & gas production flow rates

The RVP current value should be imported from the Analysis:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 245


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

The Prices should now added manually without importing it

Calculate the Income, Cost & Profit using the current formulas:

Income: =d7*b7+d8*b8

Cost: =(b1+b2+b3)*d1+(b4+b5)*d4

Profit: =d12-d13

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 246


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

After calculating the operating profit @ current conditions, use the


optimizer to maximize the profit by changing the 5 variables which we
added before

Open the optimizer and go to Functions tab:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 247


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

You may need to press the Start button 2 or 3 times to ensure reaching
the optimum solution as follows:

You may see the new values for the variables from the Variables tab:

Now you can return back to the spreadsheet to observe the results:

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 248


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Save Your Case!

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 249


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

Exercise:

One thing you may notice with the Optimized solution is that the
Pressure of V3 has been decreased to 70 kPa (10 psia) which is less than
atmospheric. This is not a desired condition for the inlet of a compressor.
The inlet of the second compressor, cannot be less than 125 kPa (19 psia).
What is the maximum profit if you adhere to this guideline?

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 250


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com
Process Simulation using HYSYS V8

You may check the website for more data &


courses
http://www.adeyab.com

If you have any inquiry:


eng.a.deab@gmail.com
adeyab@adeyab.com

002 01227549943
00966544390045

By: Eng. Ahmed Deyab Fares - http://www.adeyab.com 251


Mobile: 002-01227549943 - Email: eng.a.deab@gmail.com